Insulating filler composition



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Patented June 23, 1953 EXAMINER UNITED STATES PATENT OFFICE INSULATINGFILLER COMPOSITION Louis Weber, Sr., Tacoma, Wash, assignor to WeberInsulations, Incorporated, East Chicago, Ind., a corporation of IndianaNo Drawing. Application October 6, 1948, Serial No. 53,153

2 Claims. (Cl. 106-98) The present invention relates to a new and heatinsulating properties, and which is comimproved prepared insulatingfiller; composition iaratively lowin cost and may be used with ease andconvenience.

2 slipping properties of the plaster coating upon applying the latter tothe surface to be covered. The diatomaceous earth powder serves as afiller to which the mineral and asbestos fibers may bond, and alsoserves to improve the slipping properties of the plaster coating. Inaddition, the diatomaceous earth powder is light in weight and low incost.

The colloidalmay, which may be a bentonite l0 .QIQL serves as a binderfor the other ingredients.

The proportions of the foregoing ingredients may be varied within limitswithout departing from the broad concept of the present invention. Ihave found that, for various applications,

good results are obtained by the use of a composition comprising thefollowing ingredients in the following ranges of proportions by weight.

Other objects are to provide an insulating filler Ingredients! Partscomposition of the foregoing character which, Mineral fiber 100 I whenmixed in suitable proportions withm Asbestos 3to 7 wall plaster orcement, will produce, ready for Diatomaceous earth p w r Mo 20 W6, smearcoating composition Colloidal clay 5m 15 having greatly improvedslipping properties under the action of the trowel, and having an ex- Inregard t0 the foregmng propm'tions' if more tensive spread capacity soas to cover a large surface area with minimum cost.

Still further objects are to provide a prepared insulating fillercomposition which, when used as the aggregate with a hard wall plaster,will result in a finished plaster coat which is light in weight, whichhas good heat insulating and acoustical properties, which will not checkor crack on thermal expansion or contraction, which substantiallyeliminates wall sweatin and which is fire and vermin proof,

Other objects and advantages will become apparent as the descriptionproceeds.

A filler composition embodying the features of the present inventioncomprises blown mineral fiber, such as rock wool or slag wool, asbestosfiber, diatomaceous earth powder and a colloidal clay.

The mineral fiber and asbestos fiber are ground or otherwise broken downinto suitable aggregate size. In the presence of water, these fiberparticles separate so as to obtain a substantially homogeneousdispersion throughout the massof the composition. The mineral andasbestos fibers are comparatively low in cost and light in weight. Theyhave good heat insulating properties and a tremendous water absorptioncapacity. The asbestos fiber is somewhat heavier than the mineral fiberand will absorb slightly less water than 7 parts of asbestos fiber areemployed, the weight of the composition is undesirablyincreased, and thewater absorption capacity correspondingly reduced. If less than 3 partsof asbestos fiber are employed, the desired slipping properties soughtby the use of the asbestos fiber are not realized.

If more than 20 parts of the diatomaceous earth powder are employed, thespreading properties of the plaster coating are objectionably reduced,and. the finished plaster coat has a tendency to-check. When used below5 parts, the diatomaceous earth powder does not contribute the desiredslipping properties nor sup- 40 ply the desired volume of filler.

If more than 15 parts of the colloidal clay binder are employed, theplaster coat will be subject to objectionable shrinkage and will sufferreduction in spread capacity. If less than '45 5 parts of the binder areemployed, the slipping characteristics of the plaster coat will beimpaired, and the desired bond will not be obtained.

In determining the most advantageous proportions, the objective shouldbe to provide a composition which when used as the aggregate in a hardwall plaster coating, will result in a plaster with smooth slippingproperties that is easy' to apply, and will give maximum surface spreadand heat insulation at the same time.

than the latter, but appreciably improves the The preferred compositioncomprises the follow- 3 ing ingredients in substantially the followingproportions by weight:

Ingredients: Parts Coarsely ground mineral fiber 100 Coarsely groundasbestos fiber 5 Diatomaceous earth powder Colloidal clay 10 In use, anydesired quantity of composition compounded according to the presentinvention is mixed with hard wall plaster or cement in the presence of acopious amount of water to produce a plaster mix. A satisfactory hardwall plaster coating is obtained by mixing 50 pounds of the compositionwith 100 pounds of hard wall plaster or 100 pounds of Portland cement,and 20 to 25 gallons of water. The density and consistency of theplaster mix can, of course, be controlled by varying the amount of waterthat is added. To increase the density, the amount of water is reduced.In any event, due to the high absorption capacity of the composition,the amount of water which is added can be and is greatly in excess ofthat required to cure the finished plaster coat. Because of this excesswater, it is unnecessary to sprinkle or wet the surface of the plastercoat, as is commonly done with other types of plaster, to insure propercure. After application of the plaster coat, the excess moisture notrequired for curing the plaster or cement will evaporate and thus leavethroughout the mass 9, large number of miniature air cells which greatlyenhance the heat insulating properties of the coat. Tests have shownthat a plaster spread one-half inch in thickness will afi'ord as muchthermal insulation as four inches of conventional wall fill insulation.

Plaster coating made with the present composition is very light and hasgood slipping prop- While the composition may be provided as the onlyaggregate for mixture with hard wall plaster or cement, it can becompounded with other aggregate materials such as pumice, pearlite orvermiculite.

It will be understood that in the following claims the term cement,"except as modified by adjectives, is used in its broader or genericsense and includes hard plaster as well as other cements such asPortland cement.

I claim as my invention:

1. A hardenable plastic wall coating consisting of the followingingredients in the following proportions by weight: Substantially twoparts of a cementitious material selected from the group consisting ofPortland cement and ggmmercial hard pl star; substantially one part ofan aggrega e consisting of:

Parts Mineral wool fiber 100 Asbestos fiber 3to7 Diatomaceous earthpowder 5to20 Colloidal clay 5 to 15 Water in excess of the quantityrequired to combine chemically with the cementitious material.

' following proportions by weight:

erties so that it will give an extensive spread to 0 cover a maximumarea. It affords a plaster coat and heat insulation in one application.The finished coat is tough and will not crack upon thermal expansion orcontraction of the base surface to which it is applied.

Plaster made with the present composition is especially suited forinterior wall surfacing because of its advantageous acoustical and heatinsulating properties. For this purpose, the composition is usuallymixed with hard wall plaster rather than with cement, and is commonlyapplied in from.- one to three coats as the scratch coat underneath a,finish coat of hard wall plaster. However, if desired, the scratch coatitself may be trowelled to provide a smooth surface finish.

Plaster made with the present composition is also adapted for exterioruse, as, for example, for roof decks and exterior stucco. For stuccoapplications, the composition is mixed with Parts Mineral wool fiberAsbestos fiber 3 to '7 Diatomaceous earth powder 5to20 Colloidal clay 5to 15 LOUIS WEBER, st.

References Cited in the file of this patent UNITED STATES PATENTS NumberName Date 803,285 Hayde Oct. 31, 1905 1,307,549 Headson June 24, 19191,314,772 Viens Sept. 2, 1919 1,920,358 Clark Aug. 1, 1933 1,968,489Jenkins July 31, 1934 2,033,106 Cummins Mar. 3, 1936 2,063,102 JonesDec. 8, 1936 2,275,816 Ericson Mar. 10, 1942 2,311,588 Denning Feb. 16,1943 FOREIGN PATENTS Number Country Date 497,136 Great Britain Dec. 13,1938 587,556 Great Britain Apr. 29, 1947

1. A HARDENABLE PLASTIC WALL COATING CONSISTING OF THE FOLLOWINGINGREDIENTS IN THE FOLLOWING PROPORTIONS BY WEIGHT: SUBSTANTIALLY TWOPARTS OF A CEMENTITIOUS MATERIAL SELECTED FROM THE GROUP CONSISTING OFPORTLAND CEMENT AND COMMERCIAL HARD PLASTER; SUBSTTANTIALLY ONE PART OFAN AGGREGATE CONSISTING OF: